Chip simulation of automotive ECUs

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1 Chip simulation of automotive ECUs Jakob Mauss, QTronic GmbH Matthias Simons, Daimler AG 9. Symposium Steuerungssysteme für automobile Antriebe Berlin-Tempelhof,

2 Outline of the talk Chip simulation of automotive ECUS 1. Motivation 2. Setting up a simulation 3. Performance 4. Limitations 5. Conclusion

3 Motivation ECU: more than software parameter Example: 16 x 10 map ECU memory dump

4 Motivation Engine calibration - tune more than ECU parameter - done by the OEM, not by the supplier of the ECU Process today - automated optimization of stationary states - real-time test rig or vehicle: based on the real ECU - PC based: engine and ECU both simulated, e.g. in Simulink Problems - real-time test rig: - limited reproducibility - expensive (invest, operation) - slow (real time) - PC: reverse engineering of ECU is - time consuming - complex - error prone

5 Motivation Idea move engine calibration (and other development tasks) from test rig to PC Benefit - simulation runs much faster than real time - enables use of mathematical optimization

6 Motivation Simulation of ECUs on PC: Problem: How to simulate ECU if no C source or model is available?? Ideas: - Simulate the CPU based on the hex file - Integrate this feature into MATLAB and QTronic Silver

7 Example - TCU Control Software in Silver

8 Setting up a TriCore simulation 1. write spec.txt to specify what functions to run 2. step and debug the simulation in Silver debug mode 3. generate fast running SFunction or Silver module: runs without a2l and hex

9 Setting up a TriCore simulation 1. write spec.txt to specify what functions to run 2. step and debug the simulation in Silver debug mode 3. generate fast running SFunction or Silver module: runs without a2l and hex 01 # specification of sfunction or Silver module 02 hex_file(m12345.hex, TriCore_1.3.1) 03 a2l_file(m12345.a2l) 04 map_file(m12345.map) # a TASKING or GNU map file 05 frame_file(frame.s) # assembler code to emulate RTOS 06 frame_set(step_size, 10) # Silver step size in ms 07 frame_set(text_start, 0xa ) # location of frame code # functions to be simulated, in order of execution 10 task_initial(abcde_ini) 11 task_initial(abcde_inisyn) 12 task_triggered(abcde_syn, trigger_abcde_syn) 13 task_periodic(abcde_20ms, 20, 0) 14 task_periodic(abcde_200ms, 200, 0) # interface of the generated sfunction or Silver module 17 a2l_function_inputs(abcde) 18 a2l_function_outputs(abcde) 19 a2l_function_parameters_defined(abcde)

10 generated SFunction in MATLAB/Simulink spec.txt.hex.a2l.map frame.s tcbuild characteristics turned into MATLAB workspace variables - read by S-function - may be modified by script.mexw32 MATLAB/Simulink S-function 40 MIPS.mask.txt default values for characteristics from HEX file as m script, mask for S-function block and similar Simulink snippets

11 generated virtual ECU in Silver spec.txt.hex.map.a2l frame.s QTronic tcbuild code generator virtual ECU ECU functions RTOS emulation TriCore emulation 40 MIPS.mexw32 tcbuild MATLAB/Simulink S-function 40 MIPS 4GB virtual memory A2L conversion XCP TCP/IP INCA CANape vehicle simulation or measurements on-line calibration: measure and tune running simulation tsim.dll S i l v e r TriCore debug mode 0.4 MIPS

12 Virtual ECU running in Silver: MED17

13 Performance and Limitations Run complex function for a measured scenario, 3.5 minutes target execution time MIPS Silver in debug mode sec 0.41 generated Silver module or 9.30 sec MATLAB/Simulink SFunction MED17 with TC1797, 180 Mhz sec 270 Limitations: - instruction accurate, but not cycle accurate - based on TriCore specification: 'silicon bugs' are not simulated - PCP, CAN controllers and other on chip devices not modeled

14 Summary ECU simulation on Windows PC - without expensive reverse engineering - without access to ECU source files - based on HEX, MAP and A2L file - low work effort for modeling - high accuracy of model - application example: automated calibration - works for TriCore processors: TC1796, TC1797, TC1798,... - performance: 40 MIPS

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